Flat pack friction fit furniture system

ABSTRACT

An article of furniture and associated methods and kits comprising at least one first leg support structure, at least one second leg support structure, the at least one first leg support structure being inter-fitted with the at least one second first leg support structure via an interference fit to define a support assembly, a top that is supported by and attached to the support assembly without the need for a mechanical fastener or adhesive; and means for creating a force state that attaches the top to the support assembly without the need for a mechanical fastener or adhesive, and thereby stabilizes the article of furniture, wherein the force state includes one or more forces applied to the at least one first leg support structure and the at least one second leg support structure, in addition to any frictional force from the interference fit.

APPENDIX AND INCORPORATION THEREOF BY REFERENCE

The present application is a U.S. continuation patent application of,and claims priority under 35 U.S.C. §120 to, U.S. patent applicationSer. No. 13/298,499, filed Nov. 17, 2011, which '499 applicationpublished as U.S. Patent Application Publication No. US 2012/0056463 A1,and which '499 application is a continuation patent application of, andclaims priority under 35 U.S.C. §120 to, U.S. patent application Ser.No. 12/208,849, filed Sep. 11, 2008, which '849 application published asU.S. Patent Application Publication No. US 2009/0066140 A1 and issued asU.S. Pat. No. 8,079,315, and which '849 application is a U.S.nonprovisional patent application of, and claims priority under 35U.S.C. §119(e) to, the following U.S. provisional patent applications:

-   -   (a) U.S. provisional patent application Ser. No. 60/971,651        filed Sep. 12, 2007; and    -   (b) U.S. provisional patent application Ser. No. 61/034,290,        filed Mar. 6, 2008.        Each of the foregoing U.S. patents, U.S. patent applications and        U.S. patent application publications is expressly incorporated        by reference herein in its entirety.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

BACKGROUND OF THE PRESENT INVENTION

1. Field of the Present Invention

The present invention is directed generally to articles of furniture andthe method of forming such articles from a blank of sheet material, andmore particularly, to such articles of furniture constructed from panelsengaged to form an inter-fitted construction.

2. Background

Inter-fitted furniture has been popular for many years. Past designshave required complicated assembly operations. To reduce part count,relatively thick part sections (with attendant heavy part weights)commonly have been employed. Additionally, to achieve a stable structure(e.g., a structure that resists wobbling when loaded), fasteners orcomplicated geometric structures have been necessary. Further, becauseof one or more of the foregoing, assembled structures were prone toremaining assembled and often lack ready transportability.

Despite the above efforts there has remained a need in the art forimproved inter-fitted furniture that meets one or more of the followingneeds: it is relatively easy to assemble, it is relatively easy totransport, it packages in a relatively flat and low-profile structure,it is relatively stable (e.g., it resists wobbling when loaded), it canbe manufactured in large quantities but yet allow for customization(e.g., its structure lends itself to mass-customization), it isrelatively lightweight, it is relatively easy to disassemble, itrequires no hand tools to assemble, or it can be manufactured by asystem that limits material usage and/or waste.

Examples of efforts to provide various articles of furniture includethose disclosed in Published U.S. Patent Application Nos. 20020069797;20030205180; and U.S. Pat. Nos. 401,798; 1,940,117; 2,481,671;3,338,189; 3,758,152; 4,084,517; 4,740,032; 4,765,253; 4,832,421;5,367,964; 5,644,995; 6,206,473; 6,619,749; 6,807,912; and 7,219,962,all incorporated by reference.

SUMMARY OF THE PRESENT INVENTION

The present invention meets some or all of the above-mentioned needs byproviding an improved inter-fitted furniture structure that is premisedupon a system that employs a top, and spaced apart slotted leg supportstructures that inter-fit with each other (e.g., by frictionalinter-connection of the slotted leg supports via the slots) and the topfor supporting the top. The inter-fitted furniture structure includesstructural features (e.g., structural features associated or used withthe top, the slotted leg supports, or both) that create a force state(i.e., a state of overall measurable forces that are either tensile orcompressive, and thus are other than a zero value state) that exceedsthe force obtained from frictional engagement alone, for stabilizing thefurniture structure.

In one aspect the invention contemplates an article of furniturecomprising at least one first leg support structure; at least one secondleg support structure; the at least one first leg support structurebeing inter-fitted with the at least one second first leg supportstructure via an interference fit to define a support assembly; a topthat is supported by and attached to the support assembly without theneed for a mechanical fastener or adhesive; and means for creating aforce state that attaches the top to the support assembly without theneed for a mechanical fastener or adhesive, and thereby stabilizes thearticle of furniture, wherein the force state includes one or moreforces applied to the at least one first leg support structure and theat least one second leg support structure, in addition to any frictionalforce from the interference fit.

This aspect of the invention may be further characterized by one or anycombination of the following features: at least one first leg supportstructure includes a first pair of opposing and spaced apart slotted legsupports, and the at least one second leg support structure includes asecond pair of opposing and spaced apart slotted leg supports(optionally with each leg support including spaced leg portions thatextends substantially entirely to a floor); the means for creating aforce state includes at least one cross support that connects opposingspaced apart slotted leg supports of the first or second pair with eachother in a tensile state or a compressive state of sufficient magnitudethat the supports are elastically deflected; the means for creating aforce state includes a nose portion on each of at least pair of slottedleg supports that laterally deflects and by its intrinsic elasticityapplies a lateral force against an edge of the top; the top includes oneor more notches along its side edges that engage at least one of thefirst or second leg support structures; the means for creating a forcestate includes at least one cross support that has a upper edge thatbears against a bottom surface of the top to bow the upper surface ofthe top convexly outward; the means for creating a force includes astructure that surrounds inter-fitted leg portions of the opposing andspaced apart first and second pair of slotted leg supports; the articleof furniture consists of an assembly of 7 individual parts or fewer; inits final assembled state, the article of furniture includes at leastone edge lip in at least one leg support structure has a height that isgreater than about 10 mm that is above the top; the largest thickness ofany of its parts is less than about 12 mm; the top includes a pluralityof openings in its interior; parts of the article of furniture are madefrom a faced composite material that includes a densified thermoplasticpolymeric core sandwiched between layers of metal, and the facedcomposite material has a thickness of less than about 10 mm; the topmember and the plurality of leg members are formed from a common sheetof stock material; the article is selected from a table or a chair.

In another aspect, the invention is contemplated to cover a method ofmaking an article of furniture having any of the above describedfeatures, which may comprise steps of providing a sheet of stockmaterial, cutting the first leg support structure and the second legsupport structure from the sheet, interfitting each of the parts, andcreating a force state that stabilizes the article of furniture andattaches the top, and may be further characterized by one or anycombination of the following: all parts of the article of furniture arecut from the sheet of stock material; the method further includes a stepof customizing the article of furniture; the method further includes astep of customizing the article of furniture with a photographic image,a logo, a name, or a combination thereof.

The invention also contemplates kits for any of the above describedarticles of furniture, which may include a folding carrying case thatincludes holders for the parts of the article of furniture, isfabricated from a sheet (optionally a single sheet) of a drapablematerial that folds to a thickness of less than 25 cm when all parts ofthe article of furniture are stored therein, or both.

Particularly preferred aspects of the invention contemplate an articleof furniture comprising (or perhaps even consisting essentially of) atleast one first leg support structure that includes a first pair ofopposing and spaced apart slotted leg supports; at least one second legsupport structure that includes a second pair of opposing and spacedapart slotted leg supports; the at least one first leg support structurebeing inter-fitted with the at least one second first leg supportstructure via an interference fit between the slotted leg supports todefine a support assembly; a top that is supported by and attached tothe support assembly; at least one cross support that connects opposingspaced apart slotted leg supports of the first or second pair with eachother in a tensile state or a compressive state of sufficient magnitudethat the supports are elastically deflected; and a nose portion on atleast one pair of the slotted leg supports that laterally deflects andby its intrinsic elasticity applies a lateral force against an edge ofthe top; wherein due to the cross support and the nose portion on eachof slotted leg support, a force state is realized in addition to anyfrictional force from the interference fit that attaches the top to thesupport assembly without the need for a mechanical fastener or adhesiveand stabilizes the article of furniture. Such an article may be suchthat parts of the article of furniture are made from a common sheet ofstock faced composite material that includes a densified thermoplasticpolymeric core sandwiched between layers of metal, and the facedcomposite material has a thickness of less than about 10 mm; in itsfinal assembled state, the article of furniture may includes an edge lipin at least one leg support structure having a height that is greaterthan about 10 mm that is above the top; or both; the article may bepackaged in an unassembled state in a case fabricated from a sheet of adrapable material (e.g., a polymeric film) that folds to a thickness ofless than 25 cm when all parts of the article of furniture are storedtherein; the parts are stored in the case via elastomeric holders; orany combination thereof. For example, an article of furniture herein maycomprise (or even consist essentially of) at least one first leg supportstructure that includes a first pair of opposing and spaced apartslotted leg supports, each of the opposing and spaced apart slotted legsupports including leg portions that have generally vertically orientedslots and a spanning portion that bridgingly connects the leg portions;at least one second leg support structure that includes a second pair ofopposing and spaced apart slotted leg supports, each of the opposing andspaced apart slotted leg supports including leg portions that havegenerally vertically oriented slots and a spanning portion thatbridgingly connects the leg portions; the at least one first leg supportstructure being inter-fitted with the at least one second first legsupport structure via an interference fit between the generallyvertically oriented slots of the slotted leg supports to define asupport assembly; a top that includes a plurality of notches on at leasttwo of its edges and is supported by and attached to the supportassembly; at least one cross support that connects opposing spaced apartslotted leg supports of the first or second pair with each other in atensile state or a compressive state of sufficient magnitude that thesupports are elastically deflected; and a nose portion on an at leastone of the opposing pairs of the slotted leg supports that laterallydeflects and by its intrinsic elasticity applies a lateral force againstan edge of the top via engagement of the nose portion with the notchesof the top; wherein due to the cross support and the nose portion oneach of slotted leg support, a force state is realized in addition toany frictional force from the interference fit that attaches the top tothe support assembly without the need for a mechanical fastener oradhesive and stabilizes the article of furniture; wherein all parts ofthe article of furniture are made from a common sheet of stock facedcomposite material that includes a densified thermoplastic polymericcore sandwiched between layers of metal, and the faced compositematerial has a thickness of less than about 10 mm; the article offurniture includes an edge lip in at least one leg support structurehaving a height that is greater than about 10 mm that is above the top;and the article of furniture consists of an assembly of 7 individualparts or fewer (e.g., 6 individual parts).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded perspective view of an example of an article offurniture, namely a table, in accordance with the present teachings.

FIG. 1B is a perspective view of the table of FIG. 1A in a state ofassembly including a top over a support assembly.

FIG. 1C is a perspective view of the table of FIGS. 1A and 1B is acomplete assembled state.

FIG. 1D is a plan view of the components of the table of FIGS. 1A-1C.

FIG. 1E is a perspective view of the table of FIG. 1A with the top inphantom, to illustrate how a cross-support structure applies tension fordrawing long side support structures inward.

FIG. 1F illustrates how a cross-support structure may be employed toapply a force to a top.

FIG. 1G is a perspective view of an alternative variation to the tableof FIG. 1A with the top in phantom, to illustrate how a cross-supportstructure applies tension for drawing short side support structuresinward.

FIG. 1H is a perspective view of another variation to the table of FIGS.1A and 1G with the top removed to illustrate how a cross-supportstructure applies tension for drawing short side support structuresinward and long side support structures inward.

FIG. 1I is an overhead plan view to illustrate an example how across-support structure might be employed for applying an outward bowingforce to at least two of the side support structures (shown here thelong side support structures bowed outwardly).

FIG. 1J is a perspective view of another variation of the tables of theaforenoted FIGS. 1A-1I (shown without its top), illustrating another wayin which more than one cross-support structure may be employed.

FIG. 1K illustrates how structures may include a nose portion forcreating a force state when loaded with a top.

FIG. 2A illustrates an example of an article of furniture that includesshelving.

FIGS. 2B-2D illustrate examples of variations of designs of tablesand/or individual parts of the articles of furniture herein.

FIGS. 3A and 3B illustrate how articles of furniture may be made fromsheet stock material.

FIGS. 4A and 4B illustrate a device for transporting articles offurniture parts.

FIGS. 5A-5D illustrate another approach for assembling parts to formarticles of furniture herein.

FIGS. 6A and 6B illustrate examples of cross supports.

FIG. 7 illustrates an example of a top shape.

FIGS. 8A and 8B illustrate an approach to an article of furniture thatincludes shelving, and also illustrates how supports may be varied ingeometry.

FIG. 9 illustrates another example of an article of furniture, in whichrotational symmetry is possible.

FIGS. 10A and 10B illustrate an example of a chair according to thepresent teachings.

FIG. 11 is a flow chart for a possible business method according to thepresent teachings.

DETAILED DESCRIPTION

With reference to the drawings herein, and the accompanying detailedwritten description, the present invention pertains generally to uniquearticles of furniture, methods of making and using the same, methods ofoffering such articles of furniture for sale, packaging of such articlesof furniture, and/or transportation of such articles of furniture.

In general, the articles of furniture herein will include a top (e.g., atable top or a seat surface), leg supports for supporting the top inspaced relation from a floor surface, and a structure for inducing aforce state that stabilizes the top and the leg supports.

For example one preferred approach may employ a cross-support structurethat forcibly connects at least two leg supports to each other, thatinduces a force to the top, or both. The leg supports and thecross-support structure (e.g., a cross-beam support and tensioningmember) preferably include slots which are used to interconnect and joinwith each other (e.g., in a frictional engagement). Particularlypreferred embodiments of the invention herein employ the cross-supportstructure so that a state of forces (tension, compression or both) isgenerated that imparts substantially improved stability to the overallarticle of furniture structure, thereby helping to resist wobble whenthe article of furniture is loaded, as compared with a similar articleof furniture that is devoid of such cross-support structure.

As will be illustrated with reference to the examples herein, to inducethe desired force state, particular preferred embodiments of theinvention may employ particular slotting arrangements and dimensionalfitting so that a state of forces (tension, compression or both) isrealized by virtue of the co-action of the leg supports and the top thatmay also imparts substantially improved stability to the overall articleof furniture structure, thereby helping to resist wobble when thearticle of furniture is loaded, as compared with a similar article offurniture that is devoid of such co-action.

As a result of the various structural features and interrelationshipsherein, it can be seen that a relatively strong and versatile article offurniture may realized from stock materials of surprisingly smallthickness, or relatively light weight, or both. The invention hereinthus lends itself especially well for providing one or more of portabletransporting for the consumer or end user, convenient stowing for theconsumer or end user, fuel efficient shipping, distribution, andwarehousing for manufacturers, wholesalers and/or retailers.

Turning now to FIG. 1A-1D, there is shown an example of an article offurniture, and specifically a table 10 having a longitudinal axis A_(L)and a transverse axis A_(T). The table includes a top 12, which may be apanel or other member that has an upper surface 14 and an opposing lowersurface 16 (see also FIG. 1F). As seen, the top may be generally flatand planar, with the upper surface 14 and the lower surface beingsubstantially parallel. However, other forms may be employed inaccordance with the teachings. Moreover, the top member will include anedge structure, such as a structure that includes a plurality of edges.As seen in FIGS. 1A-1D, for example, there is shown a pair of firstedges 18, and a pair of second edges 20. The pair of first edges 18, andthe pair of second edges 20 may have substantially the same length(e.g., to form generally a square top) or different length (e.g., toform generally a rectangular top, as exemplified in FIGS. 1A-1D). Thepair of first edges 18 and the pair of second edges 20 may be generallyorthogonally oriented relative to each other (as in FIGS. 1A-1D). Theymay be at an angle less than, and/or greater than, about 90° relative toeach other (e.g., to form diamond, a trapezoid, a hexagon, an octagon,or other shape). Though the edges are shown as being substantiallystraight, they may include one or more curves (see, e.g., FIG. 7). Theedges may be symmetrical or asymmetrical relative to a longitudinal axis(A_(L)) of the article of furniture, a transverse axis (A_(T)), or both.The top may also include one or a plurality of notches 22 in one or moreof the edges.

Also shown is a leg support structure. A preferred leg support structureis a panel member, which may have substantially the same thickness asthe top, as any other leg support structure employed in the article offurniture, or both. As illustrated in FIG. 1A, one such first legsupport structure 24 may include a pair of spaced leg portions 26, and aspanning portion 28 that bridgingly connects (e.g., generallyhorizontally) the spaced leg portions. The spanning portion 28 mayinclude a slot 30 a (e.g., a horizontally oriented slot) for receivingan edge of the top. For example, the slot 30 a may be substantially thewidth (w) of the top (or possibly of any tongue that may laterallyproject from the top). The leg portions 26 preferably include at leastone slot 30 b, such as a generally vertically extending slot (e.g., onethat projects upwardly from a lower end). The slot preferably may besubstantially linear and oriented generally in a single direction. Theslot has a width that is approximately the same width as the thicknessof an opposing leg portion with which it is joined in assembly, and(like other inter-fitted parts herein) preferably is sized slightlysmaller than the thickness so that a frictional engagement is possible.Any suitable geometry may be employed for the leg support structure. Asshown, the leg portions may taper to a more narrow width as ground levelis approached, the spanning portion includes a concave arcuate bottomedge that continuously curves into the leg portions. Other geometriesare also possible. The slots 30 b will typically bisect the leg portionsinto opposing portions, which optionally may be of different size and/orshape relative to each other. In this manner, the respective portionsmay be employed for helping to effectively impart beam-like resistanceto bending and assisting to realize the force state desired forstability. An upper edge 32 of the leg support structure preferably isdisposed above the slot 30 a, and will be disposed at a level higherthan the top when assembly is complete.

One or more second leg support structure 34 that is configured so thatit interconnects with one or more of the first leg support structure 24may be similarly configured. An example of such second leg supportstructure 34 may include a pair of spaced leg portions 36, and aspanning portion 38 that bridgingly connects (e.g., generallyhorizontally) the spaced leg portions. The spanning portion 38 mayinclude one or more cross support slot 40 a (e.g., shown substantiallyat the midpoint of the second leg support structure 34 in FIG. 1A) forreceiving one or more cross support 42. The leg portions 36 preferablyinclude at least one slot 40 b, such as a generally vertically extendingslot (e.g., one that projects downwardly from an upper end). The slot 40b may be substantially linear and oriented generally in a singledirection. The slot has a width that is approximately the same width asthe thickness of an opposing leg portion with which it is joined inassembly.

Any suitable geometry may be employed for any of the leg supportstructures. For the leg support structures (first and/or second), asshown, the leg portions may taper to a more narrow width as ground levelis approached, the spanning portion may include a concave arcuate bottomedge that continuously curves into the leg portions, a single spanningportion may be the only horizontally oriented structure that connectsthe spaced leg portions, an arcuate and/or straight outermost side edgemay be employed on the leg portions, corners and/or ends may be rounded,or any combination thereof. Other geometries are also possible.

The slots 40 b will typically bisect the leg portions into opposingportions that optionally may be of different size and/or shape relativeto each other, as desired, for helping to effectively impart beam-likeresistance to bending and assisting to realize the force state desiredfor stability. An upper edge 44, in which the slot 40 a is shown, mayinclude an arcuate intermediate section that provides a space (whenassembled between the edge portion in that section and the bottomsurface 16 of the top. Thus it is possible that the top of the slot 40 awill also be spaced from the bottom surface of the top. A nose portion46 may project from a corner of the structure, and preferably each uppercorner (see also FIG. 1K). A notch 48 (e.g., a generally horizontallyoriented notch, such as one having a depth less than about 10 mm, e.g.,a depth of about 5 mm) may be included proximate the nose portion, whichnotch is generally juxtaposed with an end of the upper edge 44. The noseportion may include a bulk portion that spans laterally outward of theslot, and may have nose span (NS) to its outermost edge, which may bestraight, but is shown as curved. The nose span may be at least about 5mm, more preferably at least about 10 mm. The nose span may be less thanabout 50 mm, and more preferably less than about 35 mm. As seen in FIG.1K, when a top is loaded into bearing relation with the nose portion(e.g., the top is loaded so that it inter-fits (e.g., its notch 22inter-fits) with the notch 48), the nose portion may laterally deflect(shown on right hand side of FIG. 1K) from its at rest position (shownon left hand side of FIG. 1K). For example, the slot width SW mayincrease at the top of the slot by one or two times (e.g., for amaterial having a sheet thickness of about 6 mm or less and a nose span(NS) of about 5 to about 40 mm, the nose at its top may deflect about 1to about 15 mm, more preferably about 3 to about 10 mm) its unloadedwidth. Due to its structure and material properties, in its deflectedstate, the nose portion possesses an intrinsic elasticity that causes itto apply a lateral force to the top, via its edge (e.g., a force in thedirection as shown by the arrow of FIG. 1K).

The cross support 42, generally will be a cross beam support thatincludes ends 50 a, 50 b, a first edge 52 (e.g., an upper edge that maybe flat or substantially the same shape as the bottom surface 16 of thetop) and a second edge 54 (e.g., an arcuate edge as shown). Slots 56preferably are included (e.g., substantially vertically oriented), suchas slots made from the second edge 54. Preferably, the width of theslots is of sufficient the thickness relative to the leg supports towhich they attach for providing frictional engagement therebetween. Aparticularly preferred approach is to space the slots 56 from each otherso that when they are inter-fitted with the slots 40 a of the second legsupport structure they can either draw opposing spanning portions 38inwardly (see generally FIGS. 1E, 1G, 1H, and 1J) or bow them outwardly(see generally FIG. 1I).

In FIG. 1B, there is shown a partial assembly of the table 10. It isseen that the opposing slots in first and second leg support structures(e.g., in the slots of the leg portions of each of the leg supportstructures) are inter-fitted with each other, such as by frictionalengagement to form a support assembly. The respective leg supportstructures may be assembled to each other by consecutively attachingadjoining support structures until they are all interlocked. As seen,the first and second leg support structures may be substantiallyorthogonal to each other. The assembled leg portions thus criss-crosseach other to form legs. The criss-cross configuration may such that theleg portions of each extend over at least half the entire length thelegs, more preferably over at least 75% of the entire length of thelegs, and still more preferably over at least 90% of the entire lengthof the legs. Thus, the criss-cross configuration may extend oversubstantially the entire length of the legs. One approach is to assembleall of the leg support structures and then assemble the cross support,followed thereafter by assembly of the top.

The cross support 42 is similarly inter-fitted by aligning its slots 56with the slots 40 a of the leg support structure. Frictional engagementlikewise may be used to secure the cross support with each leg supportstructure. The first edge 52 of the cross support may be substantiallyjuxtaposed with the slots 30 a of each first leg support structure 24.The first edge 52 may also be positioned in its assembled state at aheight that is different from the height of the slots 30 a. For example,the first edge may be elevated above the slots, to bow the top convexlyupward, as depicted schematically in FIG. 1F. It is also possible toremove the material of the cross support between the inner walls of theslots (e.g., between slots 56 in FIG. 6A). In this manner assembly isfacilitated by orienting the cross support generally horizontally androtating it into a vertical locked position. The slot depth may thus besubstantially reduced as compared with FIG. 6A.

As seen in FIG. 1C, the top 12 is placed onto the inter-fitted legportions, and over any cross support 42. Preferably, the first edges 18of the top will penetrate through the slots 30 a. With reference also toFIG. 1K, the walls defining the notches 22 of the top and the notches 48of the second leg support structure will abut against each other.Preferably, the co-acting inter-fit of the respective notches will alsosecure the top in a fixed position relative to the leg supportstructures. However, due to the configuration depicted herein, even inits final assembled state, the top may be free to slide against thecross support. That is, while it is contemplated that the top will be ina fixed position relative to the leg support structures, it is notnecessarily required to be fixed to the cross support, and it may bedisplaceable relative thereto.

It is possible that the length of the table will slightly exceed thelength of the distance between opposing notches 48. In this manner thenose portions 46 of the second leg support structure may deflect, andslightly spread elastically (e.g., less than about 1 cm each, and morepreferably less than about 7 mm each (e.g., about 3 to about 5 mm). Theintrinsic elasticity (i.e., the elasticity of the part that results dueto the material selected and the part geometry) of the second legsupport structure, in turn, causes a force to be applied to against thefirst edges 18 of the top, for assisting to secure the top and maintainstability of the article of furniture. It will be appreciated that otherstructures may be employed for this force application. The force, thoughillustrated as being applied longitudinally inward, may be applied inone or more other directions (e.g., the force may be appliedtransversely inward, transversely outward, longitudinally inward,longitudinally inward, or any combination that results in an overallforce state applied to the top).

The assembly of the articles of furniture herein should thus beunderstandable to the skilled artisan in view of the present teachings,including the teachings of FIG. 2 of U.S. Provisional application Ser.No. 60/971,651 filed Sep. 12, 2007, or in FIG. 2 of U.S. Provisionalapplication Ser. No. 61/034,290, filed Mar. 6, 2008, both incorporatedby reference herein. The order of assembly may be such that articles offurniture herein may be assembled so that the cross support is assembledlast. The method of assembly thus may include friction fitting the slots30 b and 40 b. Top 12 fits into horizontal slots 30 a, and notches 22inter-fit with notches 48. Upon assembly, the cross support 42 applies aforce to squeeze (or bow outwardly, as the case may be) the leg supports34, and the nose portions apply a lateral force to the top 12. Theindividual parts are thus locked securely in place, via the slottedfriction fits. Some or all of the assembly steps may take place at roomtemperature.

Other variations of the present invention are also possible. Forexample, FIG. 1E illustrates a cross support that pulls the second legsupport structures 34 toward each other, thereby effectively placing thecross support 42 in a state of tension (e.g., from the intrinsicelasticity of the second leg support structures 34). FIG. 1G illustratesa longitudinally extending cross support 42. It may operate to pull thefirst leg support structures 24 toward each other, thereby effectivelyplacing the cross support 42 in a state of tension. FIG. 1H illustratesa cross support that includes a transversely extending cross support 42and a longitudinally extending cross support 42. Each of these crosssupports may be attached to place them in tension, so that each of theleg support structures (first and second) is bowed inwardly.

Of course, as has been discussed, any of the cross supports(longitudinally extending, transversely extending, or both), may beconfigured to place them in compression from the intrinsic elasticity ofthe connected leg support structures, such as is illustrated in FIG. 1I,thereby effectively bowing the connected leg support structures outward.FIG. 1J illustrates that more than one cross support structure 42 may beemployed in either or both of the longitudinal or transverse direction.If it is desired to create a force state from the cross supports, eachsuch cross support may be employed in tension or compression inaccordance with the teachings herein.

For this embodiment and the other embodiments disclosed herein, theslots 30 a, 30 b, 40 a or 40 b generally will extend into the legsupport from one of the peripheral edges. Though shown oriented from topto bottom, or bottom to top, the direction of opposing slots may bereversed as desired. Thus, slot 40 b may extend upward from bottom andthe slot 30 b downward from the top, in contrast with that shown.

Without intending to be bound by theory, one or any combination offollowing structural features contributes to aid in strength and/orstability of the article of furniture, above described, and as to allembodiments herein: the arcuate edge geometry of individual supportparts locally defines arches that support applied loads; the presence ofa laterally applied force on the edges of the top (e.g., from thetendency of the nose portions to want to return to their unstressedstate); the presence of tension in the upper surface of the top (e.g.,from the cross support bowing it upward as in FIG. 1F); or the forcestate derived from the cross supports; the ability of the bottom surfaceof the top to move relative to any underlying support when assembled.

Further, without intending to be bound by theory, it will be appreciatedfrom the above teachings that the overall force state that is createdwill include a frictional force. However, as to all embodiments herein,it is also contemplated that the force state will include forces inaddition to frictional forces. For example, it may include tensile orcompressive forces that are induced by the intrinsic material propertiesof the parts, the geometry of the parts, or both. The overall forcestate may be sufficiently large that deflection of parts occurs, beyondany incidental or microscopic deflection that may arise due to afriction fit (e.g., due to a friction fit obtained from manual assemblyof parts by an average strength adult female assembler having a heightof about 155 to about 170 cm height and weighing about 60 to about 75kg, without using any hand tools). By way of illustration, as to allembodiments herein, for articles of furniture herein that have a topthat has a side dimension that ranges from about 20 cm to about 300 cmin length, it is possible that the force state that is created resultsin an outward deflection (as measured from its initial un-stressedposition) of one or each nose portion of the leg support structure in anamount of at least about 0.2 mm, more preferably at least about 0.5 mm,and still more preferably at least about 1 mm. It is possible that theforce state that is create results in an outward deflection (as measuredfrom its initial un-stressed position) of one or each nose portion ofthe leg support structure in an amount of less than about 10 mm, morepreferably less than 5 mm, and still more preferably less than about 2.0mm.

For all embodiments of articles of furniture herein that have a top thatranges from about 20 cm to about 300 cm in length, it is possible thatthe force state that is created by a cross support (e.g., support 42)results in a deflection (inward or outward, relative to its flat initialstate) of a mid-point of a spanning portion of the connected leg supportstructures (e.g., substantially at the location shown in FIG. 1A for theslots 40 a) of an amount of at least about 0.5 mm, more preferably atleast about 1 mm, and still more preferably at least about 2 mm. It ispossible that the force state that is created by a cross support (e.g.,support 42) results in a deflection (inward or outward) of a mid-pointof a spanning portion of the connected leg support structures of anamount of less than about 80 mm, more preferably less than about 60 mm,and still more preferably at least about 40 mm.

As the skilled artisan will recognize from the above, in a broad sensethe invention shares one or more common features that help to realizeadvantages over existing articles of furniture. By way of example, allembodiments of the present invention may share one or more of thefollowing features: the construction achieves a stable article offurniture from relatively few parts, most or all of which are panelstructures derived from sheets of stock material that have a thicknessno greater than about 20 mm, and more preferably no greater than 10 mm;the individual parts (e.g., individual panel members) that are employedto define the legs, the top, and the cross beam support may be free ofany hinge, free of any crease, free of any mechanical fastener (e.g.,screws, nails, pins, rods, dowels, clips, latches, or the like), free ofany adhesive, or any combination thereof. The articles of furniture ofthe present invention in their final assembled state may also be free ofany hinge, free of any crease, free of any mechanical fastener (e.g.,screws, nails, pins, rods, dowels, clips, latches, or the like), free ofany adhesive, or any combination thereof. The tables of the presentinvention in their final assembled state may be free of any connectedbench or seating surface. The articles of furniture of the presentinvention may be free of any slotted legs that are located in a centralregion of the articles (e.g., slotted legs may be present only in theside or end portions of the articles). Support for the top member of thearticles of furniture herein may be derived solely from the slotted legsand any cross beam support. Any cross beam support may be suspendedabove the floor (or other horizontal support surface) and be free of anydirect contact with the floor (or other horizontal support surface).

As will be appreciated from the teachings herein, the inventioncontemplates the fabrication of articles of furniture from an assemblyof patterns or cut outs that create an assembly system that can befriction fit together to create a solid stable structure, possiblywithout any mechanical fasteners. Articles of furniture herein can thenbe easily disassembled and reassembled.

The stock materials from which the support parts (or even the tops) maybe made can be any suitable material. However, it is believed that oneadvantage that can be realized from the present invention is due to theemployment of sheet stock material from which the parts are cut. Forexample, it is contemplated that a one or more sheets of stock materialare provided. Support parts and/or a top are cut from the sheet stockand thereafter assembled. Thus, it is possible that some or even allparts of the articles of furniture may be cut from the same sheet ofstock material, have substantially the same thickness or both. Referringto FIGS. 3A and 3B, there is seen an example of how a sheet of stockmaterial may be cut into individual parts that can be assembled togetherto form an article of furniture according to the present teachings.

The stock material may be any suitable dimensions. Desirably it willhave a thickness less than about 30 mm, and possibly even less thanabout 20 mm or even less than about 10 mm. For example, it may be about5 mm or less. The stock material may have dimensions from about 1 m toabout 1.5 m width and about 1 to about 2.2 m length (e.g., a 4 foot by 8foot sheet). The stock material may be substantially homogeneousmaterial. It may be a composite material. For example, it may be a facedmaterial, or other laminate. It may be a coated material. One approachherein contemplates using an aluminum faced composite board materialcalled Dibond® as the base material for the project. For example, apolymeric core (e.g., a foamed or unfoamed polyolefin such aspolyethylene, polyurethane, or other polymeric material) having one ormore faces of a metal layer (brushed, polished or coated (e.g., by stovelacquering) having a thickness of about 0.1 to about 1 mm (e.g., about0.3 to about 0.5 mm). Wood products may be employed (e.g., solid wood,plywood, particle board or otherwise). Other materials may be used, suchas metals, polymeric materials or a combination. Polymeric materials maybe used with organic or inorganic reinforcement or filler (e.g., glassfiber or glass filled). A glass top piece may also be employed. Thematerials used typically will include a core material with may beplastic, metal, wood, post-consumer recycled material, any combinationthereof or the like. The core may be substantially fully densified, orporous (e.g., it may include a polymeric foam material, such as apolyurethane foam, a polystyrene foam or otherwise). The core may have adensity per ASTM D792-08 of about 0.85 to about 0.98 g/cm² (e.g., about0.92 g/cm²).

The facing may be metal, plastic, wood veneer, woven, unwoven, or anycombination thereof. The facing may be coated or uncoated. The facingmay have a thickness on the order of about 0.1 to about 1 mm (e.g.,about 0.3 to about 0.5 mm). Thicker or thinner facings are possible too.The overall thickness of the materials for making the articles hereinwill generally be less than about 10 mm, e.g., about 2 mm to about 6 mm.Different materials may be employed for the individual components of thefurniture herein. For example, a faced composite board may be employedfor a tabletop, with one or more supports or retaining means being madeof wood, or vice versa. Other combinations are also possible.

The materials of the stock material may be deformable. Thus, it ispossible that the methods herein may include a step of forming (e.g.,thermoforming, embossing or otherwise) the stock material into athree-dimensional configuration from its originally flat state.

The stock material may exhibit a modulus of elasticity (e.g., per ASTMD638) of at least about 50,000 N/mm², and more preferably at least about60,000 N/mm² (e.g., about 70,000 N/mm²).

Another aspect of the invention is directed toward the portability ofthe articles and their individual parts. In this regard, the presentinvention also contemplates kits, which may include the individual partsdescribed herein and optionally a carrying case. The kit may thusinclude a top, a plurality of leg supports and optionally a crosssupport, all as described generally herein. The kit, in unassembledform, is packaged generally flat so that the height of the package isless than about 25 cm, or even less than about 20 cm, and morepreferably less than about 15 cm, or even less than about 10 cm. A kitmay include or consist of the individual parts described herein and acarrying case. The kit may weigh less than about 20 kg, and morepreferably less than about 15 kg (e.g., less than about 10 kg, or evenless than about 5 kg). The kit may be packaged so that it has a surfacearea for its largest outermost surface a surface area of at least about0.2 m², and more preferably at least about 0.3 m². The kit may bepackaged so that it has a surface area for its largest outermost surfacea surface area of less than about 2 m², and more preferably at leastabout 1.2 m².

For example, the articles and their individual parts are relativelylightweight and can be packaged as a kit in a low profile package thathas a relatively thin height. The kit may be provided with a carryingcase, such as a case that includes a plurality of holders for receivingthe individual parts in a predetermined location. The carrying case mayinclude one or more of a handle, a strap or some other suitable carryingor gripping device. It may include a suitable closure for maintaining itin a closed position. The carrying case may include one or a pluralityof panels that allow the case to be opened or closed. One example of apreferred case is illustrated in FIGS. 4A and 4B, which shall bediscussed herein.

Turning now to FIGS. 2A-2D, there are illustrated additional examples ofarticles of furniture in accordance with the invention. FIG. 2Aillustrates a table 60 that includes a top 62, an opposing pair of firstleg support structures 64, an opposing pair of second leg supportstructures 66. This example illustrates the optional use of one or moreshelves 68 that connect between one or both of the pair of the first orsecond leg support structures. It is possible that a cross support, suchas the cross supports 42 illustrated previously, may be employed inaccordance with the teachings herein. The table 60 may be free of suchcross support structure. Preferably stability is achieved by at leastemploying a structure as in the previously discussed embodiments, bywhich a nose portion 70 with an associated notch (such as notch 48)engages an opposing notch (such as notch 22) in the top 62. The legsupport structures are interfitted by slots, preferably so thatfrictional engagement is achieved. Each of the shelves 68 will penetratethrough the opposing pair of first leg support structures 64, such as bya horizontal slot. The shelves 68 may have locking notches, akin to thenotches 22 previously taught, that engage the opposing pair of first legsupport structures 64, such as at locking sites 72. The spacing betweenthe shelf locking notches may be less than or greater than the widthbetween upper edges 74 of each first leg support structure 64, so that atension or compression state is realized for the assembly. Each of theopposing pair of first leg support structures 64 may have one or moreopenings 76.

Articles of furniture herein may include one or more features forindividualizing or otherwise distinguishing the articles of furniture.For example, a possible step of distinguishing articles of furniture byapplying a design (e.g., a graphic design) may be employed. For example,articles of furniture may be fabricated to include a design (e.g., agraphic design) by printing the design on one or more surfaces of thearticle of furniture, etching a design into one or more surfaces of thearticle of furniture, cutting out a design from the article offurniture, applying a design as an applique or decal, or any combinationthereof. The graphic design may include a photographic image,alphanumeric text, an artistic work, a logo (e.g., a logo for a team,school, or other organization), or any combination.

For example, FIG. 2B illustrates a table 78 that includes an appliedgraphic design 80 on one or more of its surfaces. The graphic design maybe a custom design, or a stock design. The design may be printed on thetable surface, etched into the table surface, applied as an applique ordecal, or any combination. The graphic design may include a photographicimage, alphanumeric text, an artistic work, a logo (e.g., a logo for ateam, school, or other organization), an ordered pattern, a randompattern, or any combination.

By way of further example, FIG. 2C illustrates a table 82 that includesa cut-out graphic design 84 through one or more of its surfaces (e.g.,cutouts from the top). The graphic design may be a custom design, or astock design. The design may be cut out of the table material. Thegraphic design may include a photographic image, alphanumeric text, anartistic work, a logo (e.g., a logo for a team, school, or otherorganization), or any combination.

By way of yet further example, FIG. 2D illustrates a table 86 thatincludes a plurality of openings 88 in a top 90. The openings are shownscattered over substantially the entire surface of the top 90, andinclude an ordered pattern (a repetitious pattern, such as one havingholes of relatively constant sizing, spacing or both). It is possiblethat the openings are located on only a portion of the table, may be ofdifferent sizes, may be of different spacings, or any combinationthereof. Such tops may be employed for a gaming. For example, figurinesor other game pieces or figurines may include one or more pegs on abottom surface that are inserted into the openings 88, for helping tofix the position of the pieces. Another possible use of such a table mayinvolve threading a string, or other elongated fiber through theopenings to form a design that includes a plurality of interconnectedfibers threaded through the openings (e.g., elongated yarn, string, wireor cable for creating a threaded or woven design). Similarly, peggedprojecting members may extend upwardly from the top, which can beemployed for connecting a plurality of threads. Methods herein thus alsocontemplate possible steps of temporarily and removably placing peggeditems, elongated fiber members or both in the openings. Combinations ofthe embodiments of any of FIGS. 2B, 2C and 2D are also contemplated.

As discussed previously, articles of furniture herein may be made from aone or more sheets of stock material. The shapes of the individual partsmay be cut into the sheet, and the parts then separated from the sheet.It is possible that a small amount of sheet material remains fortethering the parts to the sheet, so that the sheet effectively servesas a handling frame. By way of illustration, FIGS. 3A and 3B show asheet 92 of stock material. The sheet has individual parts 94 a cut inthe sheet 92. Excess material (illustrated in various locations byreference numeral 96) of the sheet 92 can be used as a frame forgripping or otherwise manipulating sheet, with or without the parts heldtherein. The parts can be cut in any suitable manner. They may be madeby a powered cutting tool (e.g., a saw, a router, die-cutting orotherwise); they may be laser cut; scored, or otherwise cut. It ispossible that the resulting frame, upon removal of the individual parts,can be re-used, such as by hanging it on a wall as a wall-hanging, orother ornamental trim, having a motif similar to the article offurniture. FIG. 3B illustrates the frame with some of the individualparts removed from the frame, leaving openings 94 b, where the partsused to be.

As gleaned from the above, and as mentioned previously, among thepossible advantages and benefits of the various embodiments of thepresent invention is the relative ease with which the individual partsare provided, assembled, disassembled, handled and/or transported. Therelatively thin nature of the walls of the individual parts lend themwell to stacking so that a thin profile may still be maintained. Thismakes for attractive packaging and transport from one or more of amanufacturer, during sales distribution, for end-consumers. Parts may bepackaged in relatively flat packages (e.g., a generally rectangularbox). For example, the height of the package (e.g., a rectangular boxpackage) may be less than 30% of the width and/or length of the package,be less than 20% of the width and/or length of the package, or even beless than 20% of the width and/or length of the package.

Packaging may be in accordance with the teachings of FIG. 21 of U.S.Provisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein. For example, as seen in the presentFIGS. 4A and 4B, one preferred package may be a case 98 suitable fortransporting and/or storing the parts of the articles of furnitureherein may include a case including a suitable handle, strap or otherhandling device 100, individual parts 102, and a plurality of holders104 for the individual parts 102. By way of example, a case may beprovided. The case may include a layer of a textile (e.g., a wovenmaterial, a nonwoven textile material or both), a plastic, a paperproduct material, a natural fiber material, wood, metal, ceramic, or anycombination thereof. Preferably, the material is in a form that it isdrapable. For example it may be a film of less than about 30 mils (lessthan about 0.8 mm) (e.g., on the order of about 20 mils (about 0.5 mm).Examples of materials may include one or more thermoplastic sheets(e.g., vinyls, polyolefins such as polypropylene and/or polyethylene,polyethylene terephthalate, laminates or weaves of the above). Thematerial may be made from post-consumer recycled materials. The materialmay be bio-degradable. It may be based upon polylactic acid, anotherstarch-derived material, or some other agricultural by-product orrenewable raw material; it being appreciated too that any of thecomponents of the furniture taught herein may also be made of suchbiodegradable material or renewable raw material. The material may be amicroporous film. That material may be transparent over some or all ofits surface so that the components that it carries are visibly exposed.Any seams may be sealed (e.g., by a tape) or concealed. It may be scoredor hinged along one or more fold lines. It may include one or moreclosure mechanisms 106 at one or more locations about its periphery(e.g., one or more attachment device at the corners (as shown) such assnaps, zippers, hooks, buckles, clips, hook and loop fasteners, orotherwise). The inner surface of the case may include one or more meansfor holding components (e.g., holders 104) of the table or other articleof furniture. The holding means may include one or more straps (e.g.,elastomeric holders, such as straps of about 2.5 cm width (about 1inch)), one or more pockets, one or more tethers, or any combinationthereof. As indicated the case may include one or more handles 100(e.g., a strap or grip handle located along an outer edge). A handle maybe located toward a central portion of an external wall of the case aswell for improving ergonomic efficiency. In use, the components aresecured in place on an inside wall of the case, the wall is folded aboutone or more folds 108 and it is secured shut, such as with the closure.Though the use of attached hinges (with associated pivot pins) may beemployed, one preferred approach is to employ a single sheet of materialfor defining the case.

The creation of a stabilizing force state may be achieved using any of anumber of structures. As has been illustrated previously, the relativedimensions, and/or selection of locations of notches, of individualparts can be employed for inducing a force condition that helps maintainstability and/or strength of the resulting articles. One or more addedhardware devices may also be employed for helping to achieve such forcecondition. One possible approach is to employ a ring or other devicethat applies peripheral clamping or banding force to legs of the articleof furniture. With reference to FIGS. 5A-5D there is shown a table 110,constructed similarly to that of FIGS. 1A-1D (but shown optionallywithout a cross support) with a first leg support structure 112 withslots 114 in spaced legs, and a second leg support structure 116 withslots 118 in spaced legs, and optionally including one or more notches120 into which a ring 122 may be placed for bringing a nose portion 124of the second leg support structures into bearing relationship with top126 (e.g., for applying pressure to edges of the top, possible by way ofone or more notches 128 in the top, the leg support or both, as taughtpreviously).

FIGS. 5A-5D also illustrate another geometry that may be employed forslots in any of the embodiments herein. It is seen that the slots 118may be defined by opposing walls that (in their unloaded, initial state)vary in spacing along the length of the slot (here shown going fromwider spacing at the top to narrower spacing in the central part, backto wider spacing at the base of the slot). In contrast, as with otherembodiments depicted, the slots 114 are shown as being of generallyparallel opposing walls so that spacing is substantially constant alongthe slot length.

With reference to FIGS. 6A and 6B, there are shown examples of crosssupports. FIG. 6A illustrates a cross support 42, as in the embodimentsof FIGS. 1A-D, E, G, and H, 3A and 3B, 9 and 10, without limitation. Asdiscussed, it is possible that material may be removed between the slots516 for facilitating assembly. For example, the bottom edge 54 may besubstantially flat and/or extend across the support from a pointsubstantially adjoining the deepest part of the slot. FIG. 6Billustrates a cross support 42′, as in the embodiments (withoutlimitation) of FIGS. 2B, 2C, 2D or as might be employed for creating theforce state of FIG. 1I. The cross support 42′ of FIG. 6B includes alateral side wall 128 that is flanked in at least one of its ends by oneor more tongues 130, and particularly laterally projecting tongues. Theside walls are configured to bear against a leg support structure, suchas along a spanning portion of the leg support structure. The crosssupport 42′ of FIG. 6B illustrates how cross supports need notnecessarily include a straight upper edge such as first edge 52 of thesupport. An upper edge 132 might engage a bottom surface of a top overonly a portion of its length, e.g., it may include one or a plurality oflower sections 134 that may be spaced further from an adjoining top thananother section of the upper edge. It should be appreciated that eventhough a particular cross support 42 or 42′ may be shown herein for aparticular embodiment, it is possible that the other support may besubstituted. For example, the embodiment of FIGS. 1A-D, E, G, and H, 3Aand 3B, 9 and 10 may employ support 42′ of FIG. 6B (and may result in anoutward bowing of leg supports). Further, the embodiments of FIGS. 2B,2C, 2D may use support 42 of FIG. 6A instead of support 42′. Other crosssupports described herein likewise may be interchanged.

FIG. 7 illustrates an article of furniture 136, including a top 138. Thetop is depicted to illustrate how the edges of the tops need not all bestraight. As seen, one or more edges 140 may be generally straight, oneor more edges 142 may be generally arcuate, or both. Edges may employ acombination of one or more arcuate sections and one or more generallystraight sections.

With reference to FIGS. 8A and 8B, another variation is disclosed. Inthis variation, it is illustrated how the articles of furniture hereinmay include more than four legs (e.g., six legs as shown), how a shelfmay be supported in an article of furniture, how a shelf that is smallerthan any tabletop may be supported along only a portion of the length ofthe article of furniture, how leg support structures on the end maydiffer in structure relative to each other, how a shelf may be supportedby an intermediate support structure that also co-act with a long sidesupport structure to define a leg, or any combination of the foregoingfeatures (with the complete combination of the above optional featuresbeing illustrated in FIGS. 8A and 8B). As seen in FIGS. 8A and 8B, atable 144 may include a shelf 146, such as a shelf that has notches 148that engage support structures, such as a first leg support endstructure 150. The first leg support end structure 150 is shown with aslot 152 (e.g., a slot that is structured and functions like slot 30 apreviously described), through which a top (not shown) may be inserted(e.g., as in the embodiment of FIGS. 1A-1D). One or more slots 154 maybe included for receiving the shelf 146. Optionally, an opening 156 maybe formed in the first leg support end structure 150. An intermediatecross support structure 158 may be employed, which may optionally haveslotted leg portions 160 that extend toward or even all the way to afloor surface. The intermediate cross support structure 158 may alsoinclude a slot 162, through which the shelf may be inserted and againstwhich the notches 148 may bear. Another leg support end structure 150′may be employed. As shown, it has a structure like the first leg supportstructure 24 of the embodiment of FIGS. 1A-1D. However, it may beconfigured like the first leg support end structure 150, or in someother configuration. A side support structure 164 may be employed. Byway of example, it may be similar to the second leg support structure 34of the embodiment of FIGS. 1A-1D, configured to include a support forthe shelf 146. For example, it is shown with an optional slotted legportion 166 that inter-fits with the slotted leg portions 160.

The intermediate cross support structure 158 may be dimensioned in amanner functionally similar to that of the cross supports 42(42′)previously discussed so that when it is inter-fitted with the sidesupport structure 164 it bows the side support structures outwardly orsqueezes inwardly for applying a desired force.

FIG. 9 illustrates an embodiment of an article of furniture 168 that hasrotational symmetry. It includes a pair of opposing tops 170. A pair ofcross supports 172 (shown as being optionally oriented generallyorthogonally relative to each other). Though the embodiment of FIG. 9 isshown without the nose portions that bear against the top such as thepreviously described nose portion 46 and 70, such nose portion featuresmay be employed, particularly if cross supports are omitted. Further,the embodiment of FIG. 9 is shown as including an optional bowed topedge 174, which feature might be employed in any of the otherembodiments. Further, as to this embodiment, the top edge need not bebowed, but may be straight.

An article of furniture in accordance with the teachings of theinvention may be a chair that includes a plurality of slotted individualparts (e.g., a total of only six or seven individual parts) that areinter-fitted and secured in a stable configuration. With reference toFIGS. 10A and 10B, there is illustrated an example of a chair 176. Thechair includes a top 178 that is used as a seating surface (e.g., asubstantially horizontally oriented seating surface). The top may have aseating surface that is generally flat, contoured or a combination ofboth. The top may include a wall structure that defines a plurality ofopenings used to frictionally engage supports of the chair, e.g., tofrictionally engage rearward leg portions, to surround an upper part offorward leg portions (e.g., applying frictional forces, compressiveforces or both). For example, as seen in FIGS. 10A and 10B, one or bothof openings 180 and slots 182 may be defined in the top.

The chair may include a back portion that includes a back support memberconnected with at least one support, e.g., a back support member that isconnected by opposing side supports. A back portion 184 thus may bedefined to include a pair of opposing slotted side supports 186. Theopposing slotted side supports 186 may be connected via opposing endsupports 188 (e.g., a forward and rearward end support). Slotted sidesupports 186 preferably will be longer than at least the forward endsupport 188 (and preferably longer than the rearward end support also),and will thus include an upwardly projecting slotted end wall 190.

The top may rest on top of one or more cross supports similar in natureto the cross supports 42(42′) previously described. For example, asuitable cross support 192 can connect either or both of the opposingslotted side supports 186 or opposing end supports 188. For example, thecross support 192 may be oriented axially in a longitudinallyforward/rearward direction as shown, be positioned between opposing legportions 194 of the side support structure 186, or both. Similar to thenose portions described elsewhere herein, the forward end support 188may include a nose portion 196 that may extend upward (e.g., slightlyhigher than an upper edge of a spanning portion of the end support), sothat when the top is assembled onto the assembled support structure, thenose can be press fit into a lateral projection in the opening 180. Whenassembled, the height of the top of the nose portion may besubstantially the same as the upper surface of the top 178, so that itdoes not extend above the upper surface (e.g., the top of the noseportion is substantially coplanar with the adjoining region of the uppersurface of the top).

The back portion may include a slotted back support member 198, whichoptionally may include openings 200. The back support member may beinter-fitted (e.g., preferably to achieve a frictional engagement) withthe side supports 186 via inter-fitting the slots in each, consistentwith the teachings herein for inter-fitting (see, generally FIGS. 1A-1Dand associated discussion). One approach herein also contemplatesinter-fitting the side supports 186 with the front and rear end supports188 by their respective slots, preferably with the cross support alsointer-fitted.

Side supports 186 may include one or more slots, such as undercut slots202 (e.g., which may be greater than about 1 cm in length or evengreater than about 2 cm length) that receive the top 178. Side supports186 may include one or more projections, such as projections 204 thatpenetrate the opening 180 of the top. Further, the top may include oneor more nose portions 206 that have an inwardly facing wall that bearsagainst the rear end support 188 (e.g., along a side edge of an upperportion of the rear end support 188). It is seen that upon assembly asuitable stress state is created for stabilizing the chair and/orimparting strength thereto, that may include forces derived from thefrictional engagement, forces derived from any deflection of the noseportion 206 by the support 188, frictional engagement forces from thefit of the projections 204 and the upper nose portion 196 of the forwardend support, any tension or compression from the cross support 192, orany combination thereof. It is possible that additional stability mightbe imparted to the chair by the employment of a structure such as ring122 discussed previously along any of the leg portions. Further any ofthe embodiments herein might employ the opening configuration likeopening 180 of this embodiment as part of a top for helping to secureleg portions together.

The invention may also encompass business methods for the offer forsale, sale, manufacture and/or transport of articles of furniture. Dueto its simplicity of manufacture, transport, or assembly, the articlesof furniture herein lend themselves well to mass customization. Themanufacturer may maintain a large inventory of stock materials withoutregard to individual design needs of customers, and can readilycustomize articles of furniture from the inventory per customer order.That is, the stock materials can be of relatively constant size, shapeand/or thickness, which can in turn be varied to create different sizedobjects within the limits of the sheet of stock material itself. Due tothe flexibility of the product in its production, it can be cut inmultiple ways. As consumers order an article of furniture they may bepresented with a variety of choices in stock materials, designs,geometries, and/or dimensions. This can be done by supplying a papercatalog, by providing an electronic catalog, at a retail center, overthe internet, or any combination.

Certain materials can be employed that also lend themselves well tocustomization. For example, as discussed, one preferred material is afaced material, such as a composite material that includes aluminum(e.g., sheets) and a polyethylene core and is available under theDIBOND™. Preferably, the face of the material (e.g., an aluminum sheetfor DIBOND™ types of materials) accepts printed designs thereon, itaccepts a painted coating, a polyester clear-coat, or both. Thematerials also lend themselves well to customization steps that may beemployed such as etching and/or cutting out of designs from thematerial.

The top or any of the individual parts may include a hologram design, aprinted image (e.g., an ink-jet printed image) on an outer-facingsurface, an ink-jet printed image on an outer-facing surface, apolymeric coating layer on an outer-facing surface (e.g., apolyurethane-containing, acrylic-containing or methacrylic-containingcoating layer), or any combination.

Customers can be provided with choices of designs to select for applyingto articles of furniture. Examples of designs may include logos or names(e.g., logos or names of colleges or other schools, logos or names ofprofessional sports teams, logos or names of organizations, or thelike), game boards, photographs, patterns to match other decorativepatterns (e.g., carpet, bedding, upholstery, tapestry, dishes, etc.) orjust abstract designs chosen by the customer. This can employart-disclosed techniques akin to methods used for customization oft-shirts, such as is found at one or more of SPREADSHIRT.COM,CAFEPRESS.COM, THREADLESS.COM. This also offers customers theopportunity to design or buy multiple top pieces and inter-change themas needed for example if they are having a party or their kids want toplay a board game they just switch out tops. Thus, the methods hereincontemplate offering customers kits that include a plurality of tops ofdifferent designs.

Another aspect of the invention is a business method that includesemploying a website where the user enters the site can choose a standardoff the shelf model or click on customize one, similar to the t-shirtsites mentioned above. If they choose to customize one they are thenoffered a screen with sliders and a 3D view of the table that helps themadjust the size, i.e., the height, width and length based on the limitsof the material. After they have configured the size they can choose acolor. From there they can choose to either, upload a custom graphic,adjust a preset graphic, i.e., change the color scheme, pick a graphicfrom our library or have no graphic on it at all. Finally, the order isconfirmed processed packaged and shipped out the next day, ideally.

The present invention thus contemplates an approach for creating acustomized article of furniture (e.g., a table or a chair), comprisingthe steps of selecting each of the leg supports, cross support, andtabletop components for the article using a graphical user interfaceassociated with an internet website or some other computer network;storing the selection; and retrieving information about the selection ata future time; and optionally: (i) selecting fewer than all of theinitially selected components for replacing select (but not all) of thecomponents; (ii) using deign information associated with the initialselection to make selections for another table that may be different insome respect from the table created from the initial selection; or both(i) and (ii).

As shown in the flow diagram of FIG. 11, the present invention may bepurchased through a website or through a retail store. The customerselects the type of furniture (e.g., coffee table, end table, desk,dining table, the like, or otherwise), size, height, width, length, orcombinations thereof. Optionally, a type of material may be chosen or asuggested by the website of retail store. Next, a color, design, or bothmay be selected. The design may be uploaded from the customer or may beprovided from a standard set of designs. The selection are shown in afinal review of the design, which may be a panoramic image that may berotatable (e.g., a GL application or other application that has theability) to show a 360 degree view of the article of furniture. Thecustomer may approve the selected customization or revise theselections. Once approved by the customer, the customer may enter amethod of payment (e.g., credit card, Paypal®, check, the like, orotherwise) and selects shipping options (e.g., a mode of courierservices, such as UPS, FedEx, USPS, the like or otherwise). Once thepayment and shipping options are finalized, the customer may receive anemail confirmation of the order. See also, FIG. 8 from Provisionalapplication Ser. No. 60/971,651 filed Sep. 12, 2007, and U.S.Provisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein.

It is also possible to have retail point of sale manufacture of thearticles of furniture herein, wherein the customer selects the articleof furniture and at a retail store, the furniture may be scored, cut, orboth at the store, using blank sheets of material having designs and/orcolors already integrated or the customer may select a prepackagedarticle having a standard design, size, shape, or combinations thereof.The customer can then carry away the furniture from the retail store. Inthis manner, the selection by the customer, the fabrication of the partsof the article of furniture or both may be performed at a retail pointof sale, and possibly even as part of a same-day transaction.

It is possible that methods herein may include a step of offeringarticles of furniture for sale by a vendor of photographic reproductiveservices. For example, a vendor may offer an article with a top thatincludes a photographic image. The offering may be made by a vendor ofphotographic reproductive services and may be offered with two or moreother customizable products that are selected from coffee mugs, cards,posters, awards, photobooks, t-shirts, coasters, calendars, plaques, orany combination thereof.

The invention may be further characterized by one or any combination ofthe following features. Articles of furniture in accordance with thepresent teachings may be made to consist of fewer than 8 individualparts; and more preferably fewer than 7 individual parts. For example,one preferred article of furniture consists of only 6 individual parts.The individual parts of the articles of furniture in accordance with thepresent teachings may all originate from one or more sheets of stockmaterial. For example, all of the individual parts may originate from asingle sheet of stock material. It is possible that all of the partsexcept for the top member may originate from a single sheet of stockmaterial.

Among the advantages of the present invention is that a relativelystable article of furniture results from the use of relatively fewseparate parts, and optionally in the absence of any mechanicalfasteners, or other devices for coupling components. By way ofillustration, for an article of furniture that employs a tensioningmember as described herein, the article will be essentially free ofwobble (e.g., it will be free of an angular shift of any leg greaterthan about 10°, and more preferred it will be free of an angular shiftof any leg greater than about 5° from its initial unloaded position), inthe direction perpendicular to the longitudinal axis of the tensioningmember, in the direction transverse to the longitudinal axis of thetensioning member, or both.

The top member may be recessed relative to the tallest portion of theleg members. Individual parts or panel members that are employed todefine the legs, the top, and the cross beam support may be free of anyhinge, free of any crease, free of any mechanical fastener (e.g.,screws, nails, pins, rods, dowels, clips, latches, or the like), free ofany adhesive, or any combination thereof. The articles of furniture ofthe present invention in their final assembled state may also be free ofany hinge, free of any crease, free of any mechanical fastener (e.g.,screws, nails, pins, rods, dowels, clips, latches, or the like), free ofany adhesive, or any combination thereof. The tables of the presentinvention in their final assembled state may be free of any connectedbench or seating surface. The articles of furniture of the presentinvention may be free of any slotted legs that are located in a centralregion of the articles (e.g., slotted legs may be present only in theside or end portions of the articles). Support for the top of thearticles of furniture herein may be derived solely from the slotted legsand any cross beam support. Any cross beam support may be suspendedabove the floor (or other horizontal support surface) and be free of anydirect contact with the floor (or other horizontal support surface).

The interconnecting leg supports herein may connect to substantiallydefine a peripheral edge portion that is within about 8 cm, morepreferably within about 5 cm, and still more preferably within about 3cm, from a peripheral edge of a top member of the article of furniture.The interconnecting leg supports herein may connect to substantiallydefine the peripheral edge of the article of furniture.

Any slots or notches that are employed in the leg supports, the topand/or any cross support may be generally linear. Any slots or notchesthat are employed in the leg supports, the top member and/or any crosssupport may be oriented in substantially a single axial direction.

Any cross support that is used (e.g., cross support 42(42′)) may belocated toward the top of the article of furniture, proximate the ground(e.g., spaced apart from the top of the article of furniture by at leastabout 20 cm), or both. For example, it is possible that a cross supportis used at an intermediate height approximately from about ⅓ to about ⅔the height of the top.

Over at least 30% of its length (more preferably over at least 50% ofits length), the width of any interconnecting slots in any members orpanels may be approximately the thickness of the member or panel, e.g.,within about 20%, and more preferably within about 10%, so thatfrictional engagement between the interlocking components is possible.

Examples of approximate dimensions are as set forth in Table 1. Thoughnot set forth explicitly in the Table itself, the relative proportionateratios of the dimensions set forth in the Table 1 are also contemplatedas within the invention.

TABLE 1 Preferred More Preferred Most Preferred Leg slot length (SL) 5to 35 cm 10 to 30 cm 15 to 25 cm Leg slot width (SW) 1 to 20 mm 2 to 15mm 3 to 10 mm Span of leg support (SS) 25 to 80 cm 30 to 60 cm 35 to 50cm Span of cross support (0.65 to (0.70 to (0.75 to (CS) (in tension)0.98) × SS 0.95) × SS 0.90) × SS Span of cross support SS/(0.65 toSS/(0.70 to SS/(0.75 to (in compression) 0.98) 0.95) 0.90) Leg supportheight (h_(L)) 15 to about 20 to about 30 to about 80 cm 60 mm 50 mm Toplength (l) 0.2 to 1.5 m 0.4 to 1.2 m 0.5 to 1 m Top width (w) 0.2 to 1.5m 0.4 to 1.2 m 0.5 to 1 m Edge lip height (EL) 1 to 40 mm 5 to 30 mm 10to 20 mm Top panel notch depth 2 to 20 mm 3 to 15 mm 4 to 10 mm Panelthickness 1 to 20 mm 2 to 15 mm 3 to 12 mm

The ratio of leg slot length (SL) to overall leg support height h_(L) orboth may be less than about 1:4, more preferably less than about 1:3,still more preferably less than about 1:2. The ratio of leg slot lengthto overall leg length of greater than about 1:1.2, more preferablygreater than about 1:1.5, still more greater than about 1:1.8.

The ratio of leg slot width (SW) to leg slot length (SL) may be lessthan about 1:50, more preferably less than about 1:80 and still morepreferably less than about 1:100. The ratio of leg slot width to legslot length may be more than about 1:500, more preferably more thanabout 1:300 and still more preferably more than about 1:150.

When the cross support is employed it has a span CS between its slots(or between side walls 128 of FIG. 6B) that is different from the spanof slots in the leg supports that are oriented generally parallel to thecross support (e.g., the span SS of FIG. 1D). For example, the CS may bewithin at least about 5% of the SS, more preferably at least about 10%,and still more preferably at least about 15%. The CS may differ from theSS by less than about 35%, more preferably by less than about 30%, andstill more preferably by less than about 25%.

The depth of top notch 22 (from edge 18) may be less than about 3 cm,more preferably less than about 2 cm, and still more preferably lessthan about 1 cm. The depth of the top notch 22 (from edge 18) may bemore than about 0.1 cm, more preferably more than about 0.2 cm, andstill more preferably more than about 0.3 cm. For example, it may beabout 0.5 cm.

The depth of notch 48 may be less than about 3 cm, more preferably lessthan about 2 cm, and still more preferably less than about 1 cm. Thedepth of notch 48 may be more than about 0.1 cm, more preferably morethan about 0.2 cm, and still more preferably more than about 0.3 cm. Forexample, it may be about 0.5 cm.

For typical embodiments, it is contemplated that at least two edges willhave a height (referred to as the edge lip height (EL as shown in FIG.1D)) that projects higher than the upper surface of the top panel. Theedge lip height may be greater than about 1 mm, more preferably greaterthan about 5 mm, and still more preferably greater than about 10 mm. Theedge lip height may be smaller than about 40 mm, more preferably smallerthan about 30 mm and still more preferably smaller than about 20 mm. Itmay be possible that the edge lip includes one or more cutouts or otheropenings, such as an opening for providing a grip or handle so that thearticle of furniture can be lifted or lowered.

FIGS. 6A-6F of U.S. Provisional Application Ser. No. 60/971,651 filedSep. 12, 2007, and/or U.S. Provisional application Ser. No. 61/034,290,filed Mar. 6, 2008, also show several of the herein-discussedembodiments of the present invention, which are exemplary and are notlimiting. The present invention is customizable with embodiments havingdifferent sizes and heights. Furthermore, the present invention mayinclude custom designs that could either be printed on table material,etched on table material, or cut out of the table material.

Additional aspects of the invention can be gleaned from the teachingsherein, including those of FIGS. 10 through 20 of Provisionalapplication Ser. No. 61/034,290, filed Mar. 6, 2008, incorporated byreference herein, which show various alternative embodiments. Thefeatures shown in the respective embodiments are not limited solely tothose embodiments. Rather, they may be employed in combination with anyof the other embodiments. Though identified as side supports, one ormore of the supports may also be regarded as a cross support, such as isillustrated in FIG. 10 of Provisional application Ser. No. 61/034,290,filed Mar. 6, 2008, incorporated by reference herein. It will also beappreciated that the location of slots or other openings may be varied.For example, slots shown at the bottom of a leg may be re-located to atop of a leg, with a corresponding slot in a co-acting leg similarlyreversed.

Thus, for any of the embodiments herein, it will be seen that crosssupports or what have been referred to as tensioning members ofProvisional application Ser. No. 60/971,651 filed Sep. 12, 2007 orProvisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein, may generally be employed as retainingmeans; the tensioning member may function to bow the table top (e.g., inan unloaded condition) for preventing it from sagging under load (e.g.,“Tension action 2” of FIG. 10 or Provisional application Ser. No.61/034,290, filed Mar. 6, 2008, incorporated by reference herein); thetensioning member may pull opposing support members toward each otherfor assisting to provide lateral stability (e.g., “Tension action 1” ofFIG. 10 of Provisional application Ser. No. 61/034,290, filed Mar. 6,2008, incorporated by reference herein); the tensioning member may pushopposing support members away from each other (e.g., FIGS. 18 and 19 ofProvisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein); one or more tension rings may beemployed, such as around legs as shown in FIG. 12 of Provisionalapplication Ser. No. 61/034,290, filed Mar. 6, 2008, incorporated byreference herein; plural tension members may be used (as shown in FIG.14 of Provisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein); tensioning members may be employedfor tensioning more than two sides of the table (e.g., all sides of thetable may be connected by tensioning members, such as depicted in FIG.15 of Provisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein); tensioning members may have slots ornotches along side edges or bottom edges (e.g., as in FIGS. 19 and 20 ofProvisional application Ser. No. 61/034,290, filed Mar. 6, 2008,incorporated by reference herein), or even top edges, or anycombinations thereof. It will be appreciated that retaining means may beconfigured for applying a negative tension or compression of components.

For any of the embodiments herein, more than one horizontal surface ortabletop may be employed (e.g., FIGS. 16 and 17 of Provisionalapplication Ser. No. 61/034,290, filed Mar. 6, 2008, incorporated byreference herein); the sides and the cross supports may be substantiallythe same structure or otherwise allow the table to be flipped over andits bottom tabletop being used as an upper tabletop (e.g., as shown inFIG. 16 of Provisional application Ser. No. 61/034,290, filed Mar. 6,2008, incorporated by reference herein); the tabletop corners may benotched for snap-fit securing (e.g., FIGS. 16 and 17 of Provisionalapplication Ser. No. 61/034,290, filed Mar. 6, 2008, incorporated byreference herein); or any combination thereof.

Though described generally herein as employing inter-fitting ofcomponents via slots for achieving a friction fit, one or more othermodes of mechanical inter-connection engagement may be used in additionor in place of interference fits. Magnetic attachments may also beemployed for joining parts. Friction fits contemplated herein mayinclude be shrink fits, press fits or other interference fits.

Though certain embodiments herein are disclosed as tables, they are notlimited to tables but may be seating surfaces as well (e.g., they may bebenches). Accordingly, teachings herein regarding tables alsocontemplate benches or seating surfaces as well.

Further examples of additional embodiments of the present invention areshown in the following claims, herein incorporated by reference for allpurposes. References to tables are not intended as limiting. Theteachings herein may apply to other articles of furniture as well.

It will be further appreciated that functions or structures of aplurality of components or steps may be combined into a single componentor step, or the functions or structures of one-step or component may besplit among plural steps or components. The present inventioncontemplates all of these combinations. Unless stated otherwise,dimensions and geometries of the various structures depicted herein arenot intended to be restrictive of the invention, and other dimensions orgeometries are possible. Plural structural components or steps can beprovided by a single integrated structure or step. Alternatively, asingle integrated structure or step might be divided into separateplural components or steps. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention. The present invention alsoencompasses intermediate and end products resulting from the practice ofthe methods herein. The use of “comprising” or “including” alsocontemplates embodiments that “consist essentially of” or “consist of”the recited feature.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the invention. The scope of the inventionshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Without limitation, the present inventionspecifically incorporates by reference each of the drawings and theattendant verbal explanatory text therein that was present in theprovisional application Ser. No. 60/971,651 filed Sep. 12, 2007, orProvisional application Ser. No. 61/034,290, filed Mar. 6, 2008, bothincorporated by reference herein. References to drawings in suchprovisional applications also include references to any such attendantverbal explanatory text. The present invention specifically incorporatesby reference the teachings of each of the claims present in theprovisional application Ser. No. 60/971,651 filed Sep. 12, 2007, orProvisional application Ser. No. 61/034,290, filed Mar. 6, 2008, bothincorporated by reference herein.

1.-20. (canceled)
 21. A method of making an article of furniture, themethod comprising: (a) providing a sheet of stock material; (b) cuttingat least one first leg support structure, at least one second legsupport structure, and at least one top from the sheet of stockmaterial; (c) inter-fitting the first leg support structure with thesecond leg support structure via an interference fit; and (d) creating aforce state that attaches the top to the inter-fitted first and secondleg structures, thereby stabilizing the article of furniture, whereinthe force state includes one or more forces applied to the first andsecond leg support structures, in addition to any frictional force fromthe interference fit.
 22. The method of claim 21, wherein the first andsecond leg support structures and the top are cut from the same sheet ofstock material.
 23. The method of claim 21, wherein the first and secondleg support structures and the top are cut from the sheet of stockmaterial with a powered cutting tool.
 24. The method of claim 21,wherein the first and second leg support structures and the top arelaser-cut from the sheet of stock material.
 25. The method of claim 21,wherein the sheet of stock material has a thickness less than about 30mm.
 26. The method of claim 21, wherein the sheet of stock material is asubstantially homogenous material.
 27. The method of claim 21, whereinthe sheet of stock material is a composite material.
 28. The method ofclaim 27, wherein the sheet of stock material is an aluminum facedcomposite board material.
 29. The method of claim 21, further comprisingapplying a graphic design to a surface of the article of furniture. 30.The method of claim 29, wherein applying the graphic design includesprinting the graphic design onto the surface.
 31. The method of claim29, wherein applying the graphic design includes etching the graphicdesign into the surface.
 32. The method of claim 29, wherein the graphicdesign is a decal.
 33. A method of making an article of furniture, themethod comprising: (a) providing a sheet of stock material; (b) cuttinga pair of first leg support structures and a pair of second leg supportstructures from the sheet of stock material, each of the first andsecond leg support structures including a pair of opposing and spacedapart slotted leg supports; (c) cutting a top from the sheet of stockmaterial; (d) inter-fitting the pair of first leg support structureswith the pair of second leg support structures via an interference fitbetween the slotted leg supports, thereby defining a support assembly;and (e) creating a force state that attaches the top to the supportassembly, thereby stabilizing the article of furniture, wherein theforce state includes one or more forces applied to the first and secondleg support structures, in addition to any frictional force from theinterference fit.
 34. The method of claim 33, further comprising: (a)cutting a cross support from the sheet of stock material; and (b)inter-fitting the cross support with one of either the first or secondpair of leg support structures, thereby creating a tensile state or acompressive state of sufficient magnitude that the selected pair of legsupport structures are elastically deflected.
 35. The method of claim34, wherein the cross support has an upper edge that bears against abottom surface of the top to bow an upper surface of the top convexlyoutward.
 36. The method of claim 34, wherein the pair of first legsupport structures, the pair of second leg support structures, the top,and the cross support are cut from the same sheet of stock material. 37.The method of claim 33, wherein the sheet of stock material is asubstantially homogenous material.
 38. The method of claim 33, whereinthe sheet of stock material is a composite material.
 39. The method ofclaim 33, further comprising applying a graphic design to a surface ofthe article of furniture.
 40. The method of claim 33, wherein the sheetof stock material has a thickness less than about 30 mm.